This blog will be a record of my personal journey in researching, building, operating, and finally sharing my HO scale layout based on the Delaware and Hudson Railway's "Colonie Main Line."

CP Executive train in Albany

Thursday, July 6, 2017

Open Grid Benchwork: corner sections

I took a week off from work and part of the time I decided would be used for my layout. I knew I was going to need to build some corner sections for my layout... four specifically. They wouldn't have to be super fancy, but the framing would definitely not be like what I had built for the main sections. Since I have a tendency to not only over-think things but also make careless mistakes when I rush, I decided to combine these two impulses together by drawing a full-size plan of the corner sections on some poster board I had.

Not only could I identify each piece and where it fit into the plan, I could also take measurements directly from it and double-check my numbers to ensure that everything added up. And, since it didn't sound like it was going to be a lot of fun to build I also decided to make all four at the same time. That meant I needed to cut four of each piece, pre-drill all of the required holes for the wood screws and any wiring clearance holes, and label them to keep them from getting mixed up. It was an enjoyable 4-5 hours spread out over two days.

Then, I built them up in an assembly-line fashion and discovered that for the most part things went exactly as they were supposed two. A couple of wrinkles did come up though. First, one of the boards I bought from the store was too bowed to use and so I laid out everything else to make it all fit on the remaining 7 good boards and some scrap 1"x4" I had on hand. Second, I cut all the pieces correctly but one didn't look like it fit right so I assumed I messed up on measuring it and I cut all eight small boards a 1/4" shorter. I then tried them and discovered they were 1/4" too short. I don't know how I made that mistake, but I suddenly again found myself short on lumber. So, I used one piece of 2"x4" in each corner section instead of two 1x4" pieces. I labeled it "UP" to keep track of which side of the corner module is supposed to be oriented up.

I had the lumber yard cut more 15/32" plywood for the corner tops. I discovered I could get three 30" square pieces from a standard sheet, and hopefully the remaining pieces can be used to make the fourth. I may need to add additional bracing for that one to support any extra joints. Before I attached the plywood, I needed to cut and install the diagonal piece on the front of the corner sections. I discovered that some of the plywood was cut a little short in length (they apparently did not factor in the width of the saw blade), and some of my joints weren't perfectly square. Since I own a right-angle clamp, I should probably use it! So, I had to do some judicious sanding with a sheet sander I borrowed and some 40 grit paper.

Total cost for the four corner sections: $85 for the 1"x4" lumber, and $19 for the plywood, for a running total of $586. I have often wondered if I should have bought pre-made Sievers benchwork. For each of the 7-foot modules the cost would have been about $106 (a 48" long piece and a 36" long piece) and I would have needed four sides for a total of $425. Four 30" corner modules would have been $225 total. Shipping would have been $130 (20% of order). So, about $780 and that doesn't include the plywood top, or the legs, or the L-girders. I would also need to adjust cross-brace spacing and angle the corner sections. But, the benchwork would be perfectly square. Did I make the right decision? I don't know. Quality benchwork is an investment, and it isn't all about dollars and sense. Because I am making mine sectional, there are a lot more joints and plenty of room for error. But, I wanted to be able to say I built it myself. Before I lay any track I will finish all the benchwork and take stock at whether it is to a high enough standard to proceed. If not, Sievers it is.

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About Me

I am a modeler living in the Albany, NY area. I grew up in Rochester, which was Conrail territory, but moved to Albany in 2004 and was introduced to the D&H. My first love is the Arcade and Attica Railroad in western NY, of which I am both a fanatic and shareholder. And, I love anything related to British and Welsh steam railways. God Bless.